Method for Analytical Calculation of the Formability from Metallic Bipolar Plates
Abstract
:1. Introduction
1.1. Forming and Formability of Metallic Channel Plates
1.2. Investigations of Channel cross Sections
2. Materials and Methods
2.1. Definition of the Channel Parameters
2.1.1. Equation of Channel Parameters
2.1.2. Approach and Derivation
2.1.3. Validity and Restrictions
2.2. Numerical Simulation Model and Forming Experiments
2.2.1. Numerical Approach and Setup
2.2.2. Experimental Setup
2.2.3. Simulation Results and Validation with Real Process
2.3. Analytical Model
2.3.1. Motivation and Model Approach
2.3.2. Damage Factor on the Channel Radii
2.3.3. Thickness-to-Length-Ratio Factor
2.3.4. Cumulative Elongation Factor
2.3.5. Thickness-to-Height-Ratio Factor
2.3.6. Thickness-to-Length-Ratio Factor
2.3.7. General Analytical Equation
3. Results of the Analytical Model Approach and Discussion
3.1. Comparison with the Results of Qiu et al. [6]
3.2. Comparison with the Results of Zhao and Peng [5]
3.3. Comparison with the Results of Xu et al. [8]
3.4. Comparison with the Results of Our Own FE Simulations
- channel width to
- channel ground to
- inner radius to
- outer radius to
- sheet thickness to
- channel height to
4. Conclusions
- The DC calculation method described above makes it possible to obtain an initial, fast and sufficiently accurate estimation regarding to the formability of channel cross section structures in an early development process and based on this, evaluate comparatively.
- Inaccuracies in the DC method can be detected, especially in variants with extreme geometry. In the calculations, the highest deviations appear mostly by variants with very small radii, small channel flank angles or large channel depths.
- To date, the DC calculation method has only been validated on forming results based on stainless steel sheets (e.g., SS304) with relatively homogeneous (in particular non-coarse grain structure) material properties. In addition, comparisons have only been made with sheet thicknesses between and . The applicability to other materials and sheet thicknesses is to be assessed as realistic.
- In particular, when considering critical channel depths, a very good predictability has been demonstrated. At a value of the experimentally determined critical channel depth has not been exceeded in any of the cases considered. This suggests that with the support of the DC Method, it can be at least stated, with a great probability, up to which limit depth a channel structure can still be safely formed.
Author Contributions
Funding
Conflicts of Interest
References
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Position | Experiment in µm | FEM in µm | Deviation in % |
---|---|---|---|
1 | 74.0 | 74 | 0.0 |
2 | 83.2 | 83 | 0.5 |
3 | 77.8 | 76 | 2.0 |
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Keller, N.; Bauer, A.; von Unwerth, T.; Awiszus, B. Method for Analytical Calculation of the Formability from Metallic Bipolar Plates. J. Manuf. Mater. Process. 2020, 4, 1. https://doi.org/10.3390/jmmp4010001
Keller N, Bauer A, von Unwerth T, Awiszus B. Method for Analytical Calculation of the Formability from Metallic Bipolar Plates. Journal of Manufacturing and Materials Processing. 2020; 4(1):1. https://doi.org/10.3390/jmmp4010001
Chicago/Turabian StyleKeller, Nico, Alexander Bauer, Thomas von Unwerth, and Birgit Awiszus. 2020. "Method for Analytical Calculation of the Formability from Metallic Bipolar Plates" Journal of Manufacturing and Materials Processing 4, no. 1: 1. https://doi.org/10.3390/jmmp4010001